Plural layer woven electronic textile, article and method

ABSTRACT

A woven article having plural weave layers comprises a plurality of electrically insulating and/or electrically conductive yarn in the warp and a plurality of electrically insulating and/or electrically conductive yarn in the weft interwoven with the yarn in the warp. An electrical function is provided by one or more circuit carriers disposed in cavities in the plural layer woven article and/or one or more functional yarn in the warp and/or the weft, wherein the circuit carrier and/or functional yarn include an electrical contact for connecting to the electrically conductive yarn in the warp and/or weft.

This application is a divisional of U.S. application Ser. No.10/431,763, filed May 8, 2003, the entire disclosure of which isincorporated herein by reference, which claims the benefit of U.S.Provisional Application Ser. No. 60/379,723 filed May 10, 2002, and ofU.S. Provisional Application Ser. No. 60/419,159 filed Oct. 17, 2002.

The present invention relates to a woven article and method, and, inparticular, to a plural layer woven textile and/or article having anelectronic circuit woven therein, and a method therefor.

In many fields of endeavor, from military to sport to apparel, a desireexists for electronic circuits to be incorporated into fabric and intoarticles that may be made of fabric. In some instances, such as electricblankets and electrically conductive fabric, electrically resistiveand/or electrically conductive are been woven into fabric withinsulating yarn to provide the desired resistance heating and/orconductivity characteristics. In these relatively simple arrangements,the characteristics of the resistive heating yarn determines the heatingcharacteristics of the woven electric blanket and the conductivity ofthe electrically conductive yarn substantially determines theconductivity characteristic of the fabric. In other words, the numberand size of electrically conductive yarn determine the conductivity ofthe fabric.

Apart from the aforementioned relatively simple arrangements, whereelectrical functionality of greater complexity has been desired,electrical circuits have been added to fabric after the fabric is woven.Among the approaches are the lamination of electrical circuit substratesto a fabric, e.g., as described in U.S. Patent Publication No. US2002/0076948 of B. Farrell et al entitled “Method of Manufacturing aFabric Article to Include Electronic Circuitry and an ElectricallyActive Textile Article,” and the embroidering and/or applique ofelectrical conductors and circuits onto a fabric, e.g., as described inU.S. Pat. No. 6,210,771 to E. R. Post et al entitled “ElectricallyActive Textiles and Articles Made Therefrom” and in an article by E. R.Post et al entitled “E-Broidery: Design and Fabrication of Textile-BasedComputing” published in the IBM Systems Journal, Volume 39, Numbers 3 &4, pages 840-860, 2000. In addition, an arrangement attaching electricalcomponents to woven fabric including conductive yarn, such as byconnecting the components to the conductive yarn by soldering and/or byelectrically conductive adhesive, is described in U.S. Pat. No.6,381,482 to Jayaraman et al entitled “Fabric or Garment With IntegratedFlexible Information Infrastructure.”

In the aforementioned arrangements, the electrical electronic functionis added after the fabric has been woven, e.g., by embroidery or byapplique or by mechanical attachment, thereby adding additional stepsand additional complexity to the manufacturing process. In addition, theparticular arrangement thereof appears to be suited to one specificapplication or usage with corresponding specific manufacturing, and doesnot appear to lend itself to an efficient, relatively generalmanufacturing wherein the function and operation of the resulting fabricneed not be specified or determined until after the fabric is woven,i.e. manufactured.

Accordingly, there is a need for a woven textile and article having anelectronic circuit function woven therein.

To this end, the multilayer woven article of the present inventioncomprises warp yarn and weft yarn interwoven in a multilayer weavehaving plural layers defining at least one cavity therebetween, at leastone electrically conductive yarn disposed in the warp and/or in the weftand having a portion thereof in one of the plural layers defining the atleast one cavity, and a circuit carrier disposed in the cavity andhaving at least one exposed electrical contact in electrical connectionwith the at least one electrically conductive yarn, the circuit carrierincluding at least one electronic device for performing a function.

According to another aspect of the invention, a multilayer woven articlecomprises a plurality of electrically insulating yarn and electricallyconductive yarn defining plural layers in the warp, a plurality ofelectrically insulating yarn and electrically conductive yarn in theweft interwoven in a multilayer weave with the plurality of electricallyinsulating yarn and electrically conductive yarn in plural layers in thewarp, wherein an electrically conductive yarn in the warp crossing anelectrically conductive yarn in the weft makes electrical connectiontherewith at the crossing thereof, and at least one electricallyconductive yarn in the warp and/or in the weft woven into at least firstand second ones of the plural layers for crossing at least oneelectrically conductive yarn in the other of the warp and/or weftwithout making electrical contact therewith.

BRIEF DESCRIPTION OF THE DRAWING

The detailed description of the preferred embodiments of the presentinvention will be more easily and better understood when read inconjunction with the FIGURES of the Drawing which include:

FIG. 1A is a plan view schematic diagram of an example woven fabricincluding an example embodiment of an electronic circuit therein;

FIG. 1B is an isometric schematic view of a portion of an examplemultilayer woven fabric including an example embodiment of an electroniccircuit therein;

FIG. 2 is a plan view schematic diagram of a yarn including an exampleelectronic circuit function, as for the woven fabric of FIGS. 1A and 1B;

FIGS. 3A through 3D are plan view schematic diagrams of exampleembodiments of yarns including an example electronic circuit functionsuitable for a woven fabric as illustrated in FIGS. 1A and 1B;

FIGS. 4A, 4B and 4C are plan view schematic diagrams of an exampleembodiment of a circuit carrier including an example electronic circuitfunction suitable for a woven fabric as illustrated in FIGS. 1A and 1B,and FIG. 4D is an isometric view thereof when folded;

FIG. 5 is a partial cross-sectional schematic diagram illustrating anexample circuit carrier disposed in a cavity of a multilayer wovenfabric;

FIGS. 6A and 6B are schematic diagrams illustrating example loomarrangements suitable for making example embodiments of fabric describedherein;

FIG. 7 is a schematic diagram of an example carrier insertionarrangement and an example roller arrangement suitable for weaving andfinishing fabric woven in accordance with FIGS. 6A-6B;

FIG. 8 is a schematic diagram of an example yarn including an exampleelectronic circuit function suitable for use with the example loomarrangements of FIGS. 6A-6B; and

FIG. 9 is a schematic diagram of an example woven textile illustratingan ordinary weave and a complex weave useful in connection with thearrangements of FIGS. 1A to 3B.

In the Drawing, where an element or feature is shown in more than onedrawing figure, the same alphanumeric designation may be used todesignate such element or feature in each figure, and where a closelyrelated or modified element is shown in a figure, the samealphanumerical designation primed may be used to designate the modifiedelement or feature. It is noted that, according to common practice, thevarious features of the drawing are not to scale, and the dimensions ofthe various features are arbitrarily expanded or reduced for clarity.

DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

Woven textiles generally comprise two sets of relatively straight yarn,the warp and the weft, which cross and interweave to form a fabric.Typically, the warp and weft yarn cross at approximately a right angleas woven, but may cross at any angle. Also typically, fabric is woven tohave a given width, but may have any desired length. The warp yarn runsin the length direction of the fabric, which is generally the longerdimension thereof, and the weft yarn runs in the crosswise or widthdirection thereof, which is generally the shorter dimension. With amodern computer controlled loom, the weaving process is performedautomatically and may be responsive to weaving instructions described incomputer instructions and/or derived from a computer aided designprogram. More complex weaves, such as a Leno weave in which a pair ofwarp yarn are intertwined in a series of figure eights with fillingyarn, may employ more than two sets of yarn and/or other than a plainweave in the warp and/or weft, are readily made by such modern looms.

A textile and/or fabric may be woven in a single-layer weave and/or in aplural-layer weave. It is noted that textiles and/or fabrics having twoor more layers, i.e. plural layers, are commonly and generally referredto as multilayer weaves. Certain weaves may be referred to specifically,e.g., a two-layer woven fabric may be referred to as a double weave.Double and other multilayer weaving is conventional and is described inmany publications, e.g., D. Chandler, Learning to Weave, InterweavePress, 1995, Lesson 10, “Double Weave.”

In a plural layer (multilayer) weave, warp yarn are designated as beingin one of two or more layers and the weft yarn is interwoven with warpyarn in any one or more layers, so as to weave fabrics having other thana single-layer sheet-like construction. One or more layers, tubes,pockets, cavities, or other complex woven structures may be providedutilizing multilayer weaving, e.g., by providing one or more regionswherein two overlying layers of weave are not interwoven in theregion(s) and the one or more regions are interspersed among andsurrounded by regions wherein the multiple layers are interwoven. Anyand all of such regions wherein plural layers are not interwoven may bereferred to as “pockets” for simplicity, or generically and formally as“cavities.”

The yarn, which is typically long, flexible and relatively thin, isselected to provide the desired strength, wear, laundering, durabilityand other requirements of the end use to which the fabric is intended tobe put. Where ones of the warp and/or weft yarn are electricallyconductive, the woven fabric may function in a manner akin to anelectrical circuit board, i.e. the electrically conductive yarn provideelectrical connections between various locations of the woven fabric,and/or to locations external to the fabric, and/or with electricaland/or electronic components embodied in the fabric, as may be desired.

The embodiments of woven textile and/or fabric herein generally includea carrier including an electronic circuit for performing all or part ofan electronic function. Examples of such carriers include circuitcarriers, also referred to as carriers, modules or “circuit tablets” insome cases, and “functional yarn.”

A circuit carrier is a relatively compact part including one or moreelectronic parts and/or devices and interconnections therebetween, andthat also has one or more exposed contacts at which electricalconnection to conductive yarn in a textile or fabric may be made. One ormore circuit carriers may be placed into cavities formed in a woventextile or fabric, e.g., as by weaving a pocket, tube, or other cavityby plural layer or multilayer weaving. The arrangements herein includecircuit carriers in a woven textile or fabric that has one or moreelectrically conductive yarn in the warp and/or the weft.

Another example of a circuit carrier is referred to herein as a“functional yarn” which may be in the warp and/or the weft, but istypically in the weft. Functional yarn includes an elongated electricaland/or electronic substrate on which are disposed one or more electricalconductors and a plurality of electrical and/or electronic devices thatconnect to one or more of the electrical conductors. In other words, afunctional yarn is any electrical and/or electronic substrate thatincludes electrical conductors and electrical and/or electronic devicesthat perform an electrical and/or electronic function, wherein thesubstrate may be utilized as a yarn and woven.

FIG. 1A is a plan view schematic diagram of an example woven fabric 100including an example embodiment of an electronic circuit, and FIG. 2 isa plan view schematic diagram of a yarn 150 including an exampleelectronic circuit function, as for the woven fabric of FIGS. 1A and 1B.Fabric 100 is a plain weave fabric including insulating yarn 110 andelectrically conductive yarn 120 in the warp and insulating yarn 130 andfunctional yarn 150 in the weft. Fabric 100 may also includeelectrically conductive yarn in the weft. Insulating yarn 110 aredisposed between adjacent electrically conductive yarn 120 in the warpto provide an insulating separator therebetween and insulating yarn 130are disposed between adjacent functional yarn 150 (and/or electricallyconductive yarn, if any) in the warp to provide an insulating separatortherebetween.

FIG. 1B is an isometric schematic view of a portion of an examplemultilayer woven fabric 100′ including an example embodiment of anelectronic circuit. Example fabric 100′ is a multilayer weave fabric,specifically a three-layer weave, including, e.g., insulating yarn 110and electrically conductive yarn 120 in the warp of each of layers 101and 103, and including, e.g., insulating yarn 130, electricallyconductive yarn 140 and functional yarn 150 in the weft. Example layer102 includes insulating yarn 110, 130 in the warp and weft so as toprovide an insulating separation between the conductive yarn 120, 140disposed in layers 101 and 103. Layer 102 may include electricallyconductive yarn 120 and/or functional yarn 150 in the warp, butelectrically conductive warp yarn 120 and/or functional yarn 150 may beincluded only where not proximate conductive warp yarn 120 in either orboth of layers 101 and/or 103 so as to avoid short circuits. Examplefabric 100′ may include functional yarn 150 in the warp and/or in theweft. Insulating yarn 110 are disposed between adjacent electricallyconductive yarn 120 in the warp to provide an insulating separatortherebetween and insulating yarn 130 are disposed between adjacentfunctional yarn 150 and/or electrically conductive yarn 140 in the warpto provide an insulating separator therebetween.

Ones of the weft yarn, e.g., ones of weft yarn 130, 140, 150, areinterwoven with ones of warp yarn 110, 120 (and with ones of warpfunctional yarn 150, if any) in warp layers 101, 102, 103, to weave amultilayer fabric. In the fabric portion illustrated, one warp yarn 140a is interwoven with layers 101, 102 and 103 and another warp yarn 140 bis interwoven with layers 102 and 103. The combination of multilayerinterwoven electrically conductive yarn 120 and/or functional yarn 150in the warp and electrically conductive yarn 140 and/or functional yarn150 in the weft provide a multilayer structure having electricalconductors and/or functions on one or more layers, thereby to provide anelectrical structure somewhat analogous to the structure of a multilayerlaminated electronic printed circuit board.

It is noted that while known electrically conductive yarn is completelyuninsulated, partially insulated electrically conductive yarn could beemployed in the textiles, fabrics and/or articles described herein,wherein the uninsulated portions thereof are woven to be in locationswhereat electrically connection is to be made thereto, e.g., atcrossings of other electrically conductive yarn and/or of functionalyarn to which electrical connection is to be made. As used herein, theterms electrically conductive yarn and uninsulated electricallyconductive yarn are used interchangeably to refer to electricallyconductive yarn that is completely or partially uninsulated.

Interweaving of plural adjacent weft yarn, typically insulating yarn 130and electrically conductive yarn 140 between two or more warp layers101, 102, 103, can be woven to form pockets, tubes or recesses, e.g., assuggested by cavities 106 a, 106 b, into which circuit carriers may beplaced. Preferably, cavities 106 are woven to be closed pockets and thecircuit carriers are inserted into the pockets during the weavingprocess and are enclosed therein as the pockets are woven, as describedbelow. Typically, adjacent layers are interlocked by weft yarn 130, 140,however, they can be woven as separate layers, as they are to form acavity or pocket as described. An external or surface layer wholly ofinsulating yarn may be woven as an outer layer so as to provideinsulation of the conductive yarn 120, 140 and functional yarn 150included in the inner (enclosed or internal) layers.

Functional yarn 150 of FIG. 2 includes plural electrical conductors 154,156, 158 and an electronic device 160 on an insulating electrical orelectronic substrate 152. In the specific example of FIGS. 1 and 2,electronic device 160 is a light emitting diode (LED) 160 that emitslight in response to electrical signals applied thereto. Substrate 152is an elongate strip of flexible insulating material, e.g., a polyimideor polyester or other material suitable for use as an electricalsubstrate. Conductors 154-158 are formed on substrate by any suitablemeans, such as by etching a conductive metal layer, e.g., copper layer,attached to substrate 152 using known methods for making flexibleelectrical printed circuits and the like. As illustrated, conductor 154extends substantially the length of substrate 152 to provide a commonconnection to all of the LEDs 160 thereon, and an electrical signal foractivating LEDs 160 is applied thereto. Conductor 158 provides anelectrical contact 158 to which an electrical signal for activating LED160 is applied, and each contact 158 is connected to a corresponding LED160 by a conductor 156.

Electrical connection between electrically conductive yarn 120 in thewarp and functional yarn 150 and/or electrically conductive yarn in theweft is satisfactorily made by the physical contact therebetween in aplain weave having a typical tightness and/or density of yarn, withoutany mechanical attaching thereof. Optionally, the electrical connectionprovided by physical contact, e.g., frictional contact, may besupplemented, e.g., by a mechanical attaching such as a spot ofelectrically conductive adhesive or solder, at each connection 158. Forproper electrical contact, functional yarn 150 is registered so thatcontacts 158 thereon each underlie a conductive yarn 120 where theycross. To this end, functional yarn 150 may include one or moreregistration marks or indicia 180 at one end thereof so that the loommay sense the position thereof in the weaving process to provide properregistration.

Optionally, conductor 154 and/or contacts 158 may be coated with aninsulating coating, except at locations where an electrical connectionis to be made thereto. Also optionally, conductor 154 and/or contacts158 may have a spot of electrically conductive adhesive applied atlocations where an electrical connection is to be made thereto, e.g., atthe terminal locations for LEDs 160 and/or at intersections withconductive yarn 120. LEDs 160 may be connected to substrate 152 by anysuitable means, e.g., by soldering or electrically conductive adhesive.

Each LED 160 is illuminated by applying a suitable electrical signalbetween common conductor 154 and the contact 158 associated with theLED. In fabric 100, each conducting yarn 120 intersects functional yarn150 to overlie one of the contacts 158 thereof. Thus, each LED 160 hasone terminal that is connected via contact 158 to a conductive yarn 120that is accessible at an edge of fabric 100 and has a terminal connectedto conductor 154 that is accessible at another edge of fabric 100, andso each LED 160 may be activated by applying an electrical signal to theappropriate ones of conductive yarn 120 and conductors 154. LEDs 160 offabric 100 are in aggregate an addressable passive-matrix display havingrow conductors 120 and column conductors 154 by which any one or more ofLEDs 160 may be addressed. Alternatively and optionally, acurrent-limiting resistor R could be provided for each LED 160 or forgroups of LEDs 160, of functional yarn 150.

Fabric 100 as described is a woven passive-matrix display wherein anypattern of the LEDs 160 may be illuminated by applying appropriateelectrical signals between selected ones of conductors 120 and 154.However, with additional conductors and/or electronic devices onfunctional yarn 150, an active-matrix display and/or a non-matrixdisplay and/or a display having individually addressable pixels (LEDs)may be provided, as described below. Thus, LEDs 160 or any otherelectronic devices 160 may be energized and/or operated in a programmedpattern and/or sequence, e.g., to provide an alphanumeric or othercharacter display, or a pixilated display, or to provide a sensor arrayfabric that sequentially senses different agents and/or processes thesensed data.

It is noted that in an actual application, e.g., a textile or textilearticle, fabric 100 would likely be much larger and would contain manymore yarn of one or more types in both warp and weft, and functionalyarn 150 would likely be much longer and contain many more LEDs 160.Thus, FIGS. 1 and 2, as well as other FIGURES herein, may be consideredas illustrating a portion of a fabric or a portion of a functional yarn.

Suitable insulating yarn includes, for example, but are not limited to,yarn and/or thread and/or fiber of cotton, wool, silk, linen, flax, silkorganza, synthetics, plastic, polyester, and the like, whether fiber,thread, monofilament, multi-stranded, spun, twisted or otherwiseconstructed, as may or may not be conventional.

Suitable electrically conductive yarn includes, for example, but is notlimited to, copper, steel, stainless steel, nickel, silver, gold and/orother metal threads, whether single filament or plural stranded, twistedor braided or a wire or a flat strip, combinations of conductive metaland insulating threads and/or strands, electrically conductive plastics,and the like. One suitable electrically conductive yarn is Aracon® yarnwhich comprises one or more strands or threads of a metal-coated Kevlar®polymer and is commercially available from E.I. duPont de Nemoirs andCompany of Wilmington, Del. Aracon® yarn can have an electricalconductivity approaching that of copper, e.g., about 10⁻³ Ohm/cm. Othersuitable conductive yarn include metal-wrapped yarns and metal-platedyarn, and the like.

FIGS. 3A through 3D are plan view schematic diagrams of exampleembodiments of yarns 150 a, 150 b, 150 c, including an exampleelectronic circuit function suitable for a woven fabric as illustratedin FIGS. 1A and 1B.

FIG. 3A is a plan view schematic diagram of a yarn 150 a includinganother example electronic circuit function, as for the woven fabric ofFIGS. 1A and 1B. Functional yarn 150 a includes plural electricalconductors 154, 155, 156 and an electronic device 160 on an insulatingelectrical or electronic substrate 152. In this specific example,electronic device 160 is a sensor, such as a temperature sensor.Substrate 152 is an elongate strip of insulating material, e.g., apolyimide or polyester or other material suitable for use as anelectrical substrate.

Functional yarn 150 a is viewed from the “back” as if substrate 152 istransparent so that conductors 154, 155, 156 on the front surfacethereof, and sensors 160 attached thereto, are visible. Conductors154-156 are formed on substrate 152 by any suitable means, such as byetching a conductive metal layer, e.g., copper layer, attached tosubstrate 152 using known methods for making electrical printed circuitsand the like. As illustrated, each of conductors 154, 155 and 156 extendsubstantially the length of substrate 152 to provide three commonconnections to all of the sensors 160 thereon. Conductor 154 provides acommon or ground connection, conductor 156 provides via contacts 166 aconnection for electrical power for each sensor 160. Conductor 155provides a conductor and contact 165 for applying an electrical signalfor activating and/or reading sensor 160 and for receiving an electricalsignal comprising data or information read from sensor 160.

Electrical connection between electrically conductive yarn 120 in thewarp and conductors 154, 155, 156 of functional yarn 150 a and/orelectrically conductive yarn in the weft is satisfactorily made by thephysical contact therebetween in a plain weave having a typicaltightness and/or density of yarn, and may be supplemented, e.g., by aspot of electrically conductive adhesive at each connection 158. Forproper electrical contact, functional yarn 150 a is registered so thatcontacts 158 g, 158 d, 158 p thereon each underlie a respectiveconductive yarn 120 where they cross. To this end, functional yarn 150 amay include one or more registration marks or indicia 180 at one endthereof so that the loom may sense the position thereof in the weavingprocess to provide proper registration.

Optionally, conductors 154, 155 and/or 156 may be coated with aninsulating coating, except at locations 158 g, 158 d, 158 p to definecontacts 158 g, 158 d, 158 p where an electrical connection is to bemade thereto. Also optionally, contacts 158 g, 158 d, 158 p may have aspot of electrically conductive adhesive applied for making anelectrical connection is to be made thereto., e.g., at intersectionswith conductive yarn 120. Sensors 160 may be connected to substrate 152by any suitable means, e.g., by soldering or electrically conductiveadhesive.

Electronic device 160 is preferably an addressable sensor which has aunique identification or address and which, when signaled by a datasignal including such identification and/or address via its dataterminal 165, performs a particular function. The function performed maybe as simple as sensing a presently existing condition, such astemperature, or recording a given condition over a time period, whetherfor a given period or until again signaled, or may be more complex, suchas providing processed data relating to a sensed condition. Each sensor160 is powered by electrical power applied between ones of conductingyarn 120 connected to conductors 154 and 156 of functional yarn 150 aand is activated by applying a suitable electrical addressing signalbetween common conductor 154 and data conductor 155, i.e. between twoconducting yarn 120. One example of a suitable addressable sensor istype DS18B20X temperature sensor and/or thermostat flip-chip integratedcircuit and the like available from Dallas Semiconductor—MaximIntegrated Products, Inc. located in Sunnyvale, Calif.

In a fabric 100, each conducting yarn 120 intersects functional yarn 150a to overlie one of the contacts 158 thereof. Thus, each sensor 160 hasterminals that are connected via contacts 158 g, 158 d, 158 p to aconductive yarn 120 that is accessible at an edge of fabric 100, so thatall of sensors 160 on all of functional yarn 150 a of fabric 100 areaccessible from a single edge of fabric 100. In addition, whereconductive yarn 120 are in the warp and functional yarn 150 a are in theweft, fabric 100 may be woven to any desired length and be connected atone edge in the same format, e.g., at a single interface that may bestandardized. Alternatively, fabric 100 may be cut into any desiredlength and each length may be connected via the standardized interface.Also alternatively, conductors 154, 155, 156 may be continuous oversubstantially the length of functional yarn 150 a in which case onlythree conductive yarn 120 may be necessary to address addressablesensors 160, or conductors 154, 155, 156 may be discontinuous over thelength of functional yarn 150 a in which case more than three conductiveyarn 120 may be necessary to address sensors 160.

Thus, sensors 160 of fabric 100 are in aggregate an addressable sensormatrix display having conductors 120 available at a single edge by whichany one or more of sensors 160 may be addressed. It is noted that in anactual application, e.g., a textile or textile article, fabric 100 wouldlikely be much larger and contain many more yarn of all types in bothwarp and weft, and functional yarn 150 would likely be much longer andcontain many more sensors 160. Thus, FIGS. 1A and 1B, as well as otherFIGURES herein, may be considered as illustrating a portion of a fabricor a portion of a functional yarn.

Circuit carriers, connectors and/or batteries and/or other componentsneeded to connect with and/or operate fabric 100 may be attached to orincorporated into fabric 100, e.g., in cavities 106 woven therein and/orat an edge or edges thereof and/or at another convenient location.Examples of such components include, for example, decoders and/ordrivers for LEDs, and/or for one or more rows and/or columns of LEDs,however, such components are preferably disposed on functional yarn 150.

Alternatively and optionally, electronic devices 160 may be of the sortthat derive their operating power from the data and/or signals on thedata conductor 155. Alternatively, electronic devices 160 may be poweredvia power conductor 156 by superimposing the data and/or signals on thepower signal. One example of a sensor device 160 suitable for sucharrangement is the type DS18B20X temperature sensor available fromDallas Semiconductor—Maxim Integrated Products, Inc. Thus, a functionalyarn 150 a may be, for example, a two-conductor equivalent of thethree-conductor functional yarn 150 a of FIG. 3A. Other addressingarrangements, e.g., those requiring more than three conductors, such asthe I²C scheme which requires a clock signal conductor, may also beemployed.

FIG. 3B is an example embodiment of a functional yarn 150 b whichincludes additional electronic devices 170 on functional yarn 150, asmay be employed to provide a woven non-matrix display havingindividually addressable pixels (LEDs) 160. Extending substantially thelength of substrate 152 is conductor 154 connecting to all of thedevices 160 at terminal 164 thereof and to electronic devices 170 atterminal 174 thereof, e.g., for providing a ground connection. Extendingsubstantially the length of substrate 152 is conductor 158 connecting toall of electronic devices 170 at terminal 178 thereof, e.g., forproviding a power connection. Also extending substantially the length ofsubstrate 152 is conductor 155 connecting to all of electronic devices170 at terminal 175 thereof, e.g., for providing a data signal theretofor addressing electronic devices 170 for selectively applyingelectrical power from conductor 158 to terminal 168 of LED 160 viaoutput terminal 176 and conductor 156. As above, functional yarn 150 bmay include one or more registration indicia 180.

Electrical power is thus applied to all of electronic devices 170 viapower conductor 158 and is selectively applied to ones of electronicdevices 160 via the ones of electronic devices 170 that are addressed bythe addressing signals, e.g., serial addressing signals, provided viadata conductor 155. Electronic device 170 is preferably an addressableswitch which has a unique identification or address and which, whensignaled by a data signal including such identification and/or addressvia its data terminal 175, performs a particular function. The functionperformed may be as simple as making or breaking a connection betweentwo of its terminals 176 and 178, whether for a given period or untilagain signaled, or may be more complex, such as providing awidth-modulated or time modulated or a frequency signal at or betweenone or more of its terminals.

In a functional yarn 150 b for a simple non-scanned, non-matrix array oflight-emitting pixels, the state of each pixel may be set by addressingthe appropriate switch and setting its state, e.g., either “on” or“off,” to set the state of the pixel to either “on” or “off.” Oneexample of a suitable addressable switch is type DS2406 available fromDallas Semiconductor—Maxim Integrated Products, Inc. located inSunnyvale, Calif. Alternatively, addressable switch 170 has pluralcontrollable outputs for controlling plural electronic devices 160. Inone embodiment, addressable switch 170 has seven outputs, as would beconvenient for addressing a seven-segment LED display for displaying thenumbers 0-9.

Such functional yarn 150 b and a woven fabric display including same,employs serial addressing and is suitable for displaying still imagesand/or text or character messages. A fabric display may also be utilizedfor displaying moving images, e.g., video-rate displays, if sufficientaddressing bandwidth or parallel addressing is available. Because an LEDis emissive, it can produce a display that is not only easily seen inthe dark, but may also be seen in daylight.

FIGS. 3C and 3D are an example embodiment of a functional yarn 150 cwhich includes power and ground conductors 154, 156, various resistorsR, and electronic devices 160 on functional yarn substrate 152, as maybe employed to provide a woven non-matrix display having a pattern ofelectronic devices 160, e.g., LEDs 160, thereon. In particular,functional yarn 150 c has a yarn substrate 152 that may be utilized withvarious different ones of devices 160 and resistors R attached thereto,e.g., in various serial and/or parallel circuits, as may be advantageousfor making a unique and/or a specialized functional yarn. A portion ofyarn substrate 152 is shown in FIG. 3D without electronic devices 160and resistors R mounted thereon.

Spaced apart at a pitch 2P along the opposing edges of substrate 152 areconductor patterns 158 and 159 having respective contacts 158 a, 158 dand 159 a and 159 d to which electronic devices 160 and resistors R maybe connected. Spaced apart at a pitch P along the opposing edges ofsubstrate 152 are pairs of contacts 158 a, 159 a of patterns 158, 159 towhich electronic devices 160 may be attached. Alternating adjacent pairsof contacts 158 a are connected to each other by a conductor 158 b whichincludes a contact 158 d extending away from the edge of substrate 152,and alternating adjacent pairs of contacts 159 a are connected to eachother by a conductor 159 b which includes contact 159 d extending awayfrom the edge of substrate 152. Conductors 158 b, 159 b are typicallydisposed alternatingly with respect to the pairs of contacts 158 a and159 a so that plural devices 160 may be connected in series, if desired,and so that contacts 158 d and 159 d alternate at a pitch 2P.

Extending substantially the length of substrate 152 of functional yarn150 c in a central region thereof is conductor 154 providing a pluralityof contacts 154 d at which a connection, e.g., to ground, may be madevia conductor 154. Also extending substantially the length of substrate152 in the central region thereof is conductor 156 providing a pluralityof contacts 156 d at which a connection, e.g., to a source of power, maybe made via conductor 156. Contacts 154 d and contacts 156 d aretypically spaced apart at a pitch 2P and are disposed so as to beproximate respective ones of contacts 158 d and 159 d so that electronicdevices 170, such as resistors R. may be mounted therebetween. Near oneor both ends of functional yarn 150 c are contacts 154 c and 156 c forrespectively connecting conductors 154 and 156 to external circuits,such as to sources of power and ground potential. Conductors 154, 156,158, 159 and the contacts thereof are typically an etched copper patternon an insulating substrate 152, and may be covered by an insulatingcoating other than at the various contacts thereof.

In the example embodiment illustrated in FIG. 3C, the five electronicdevices 160 (e.g., LEDs) at the left of the FIGURE are connected inseries via ones of conductor patterns 158, 159 and the series connecteddevices 160 are connected to conductors 154 and 156 via two resistors Rwhich are of ohmic value selected for a desired value of current flowthrough devices 160 with a specified value of potential applied betweenconductors 154, 156. Because there are two resistors R in series withthe series connected devices 160, the necessary resistance value may bedivided between the two resistors R in any desired proportion.Typically, one resistor R is of low ohmic value (e.g., 1 ohm) to serveas a jumper between one pair of connections 154 d, 158 d or 156 d, 159d, and the other resistor R is a higher ohmic value (e.g., 100 ohms)connected between another pair of connections 154 d, 158 d or 156 d, 159d, to determine the level of current flow through devices 160.

In an example embodiment of a functional yarn 150 c, substrate 152 has alength of about 40 cm and a width of about 4 mm and is of a polyimidematerial. Series connections of between one and five LEDs 160 areprovided, with contacts 158 a, 159 a each being about 1 mm by 2 mm inarea and repeating at a pitch of about 9.5 mm. Contacts 154 d, 156 d,158 d and 159 d are each about 0.5 mm by 0.5 mm, and are separated by agap of about 0.6 mm. LEDs 160 operate at a current of about 20milliamperes with about 12 volts is applied between conductors 154 and156. For five LEDs 160 connected in series, a 1-ohm resistor R and a100-ohm resistor R are utilized, whereas for a lesser number of LEDs 160in series a higher value resistor R is utilized. Where two seriescircuits of LEDs 160 draw current through the same resistor R, the valueof that resistor R is reduced proportionately so that about 20milliamperes flows in each of the two series circuits of LEDs 160. Anumber of functional yarn 150 c each having a different predeterminedpattern of LEDs 160 mounted thereto were woven into the weft of an about1.35 m by 0.37 m (about 53 inch by 14.5 inch) banner sign wherein theLEDs 160 when illuminated formed characters and/or symbols spelling outa message, e.g., “Wonders Never Cease.” Conductive yarn of braidedcopper was woven into the warp thereof to make frictional electricalconnection to contacts 154 a, 156 a of each functional yarn 150 c forapplying the 12 volt operating potential and ground potential thereto.Insulating yarn provides a desired spacing of the conductive yarn andthe functional yarn 150 c in the warp and weft of the woven sign.

LEDs 160 are caused to illuminate by applying suitable potential betweenthe terminals thereof, thereby to illuminate one or more LEDs 160 of afunctional yarn 150 individually, as a group and/or as a strip, andbrightness may be selected by suitably selecting the potential appliedand/or the current that flows. Suitable LEDs for functional yarn includethose available from Nichia Corporation of Japan, and from othersources, which may include LEDs producing “white” as well as othercolors of light, such as red, green, blue, amber and/or a combinationthereof, as well as LEDs that are switchable between two or more colors.

Examples of electrical and/or electronic devices and/or components thatmay be included on a functional yarn include, for example, but are notlimited to, sensors of temperature, chemicals, force, pressure, sound,an electric field, a magnetic field, light, acceleration and/or anyother condition, sources of light, force, heat, electromagneticradiation and/or sound, infra red and/or wireless transmitters and/orreceivers, imagers, CCD imagers, thermoelectric sensors, coolers,heaters and/or generators, liquid crystal elements, electro-luminescentelements, organic light-emitting elements, OLEDs, electrophoreticmaterials, LEDs, piezo-electric elements and/or transducers,microphones, loudspeakers, acoustic transducers, resistors, processors,digital signal processors, microprocessors, micro-controllers, CPUs,analog-to-digital converters, digital-to-analog converters, adata-producing device, a data-utilizing device, a processing device, aswitch, a human-interface device, a human-input device, a blinker and/orflasher, a battery, a fuel cell, a solar cell, a photovoltaic device, apower source, and so forth. Any one or more or all of such devices maybe activated by simply applying electrical power thereto, whether viaone or more conductors, and/or may be actively addressable in responseto an addressing signal applied thereto.

Typically, one or more conductors on a functional yarn serve to conductelectrical power and/or ground potential to electronic devices thereon,and one or more other conductors may serve to conduct data to or fromsuch devices. Sources of electrical power connected to variousconducting yarn and/or functional yarn include one or more batteries,solar cells, photovoltaic devices and/or other power sources, eitherexternal to the fabric and/or attached to the fabric and/or to afunctional yarn.

One or more data and/or signal conductors may communicate data and/orsignals to and/or from one or more external sources and/or electronicdevices on functional yarn, and/or may communicate data and/or signalsbetween electronic devices on functional yarn. All electronic devices ona functional yarn need not be of the same or like kind. For example, acombination of sensors and processors may be included on one or morefunctional yarn, whereby data is may be collected, sensed, distributedand/or processed within a functional yarn and/or plural functional yarnof a woven fabric. Thus, electronic devices on a functional yarn may benetworked together and/or may be networked with other electronic deviceson another functional yarn or external to the fabric.

Typically, functional yarn is slit or cut from a sheet of a polyimide orpolyester or other polymer material and is about 0.2 to 0.5 mm in widthand about 0.01 to 0.25 mm thick, but the material may be wider ornarrower and/or thicker or thinner. Other suitable sizes for thefunctional yarn may be in the range 0.3 to 3 mm in width and about 75 to125 μm thick. For example, an about 1 mm wide and about 0.1 mm thickfunctional yarn has been found satisfactory for weaving 0.1-0.4 meterwide fabric. On an automatic loom, e.g., such functional yarn can beinserted into the weft by a standard rapier loom. If the functional yarnis to be woven in the weft of a fabric, then it is as long as the widthof the fabric, and if the functional yarn is to be woven in the warp ofa fabric, then it is as long as the length of the fabric or longer.Although functional yarn may be similar to a conventional slit-film yarnin that it is slit from a sheet of material, it differs substantially inthat conventional slit-film yarn does not include any electrical and/orelectronic device and/or functionality as described herein.

It is noted that the functional yarn may be fabricated as a sheet orpanel of electrical substrate having electrical conductors formedthereon or applied thereto, and having electrical and/or electronicdevices attached and/or applied thereon, which sheet or panel is thencut or slit or otherwise separated into individual functional yarn. Forexample, a sheet of polyimide, polyester or other plastic suitable foruse as an electrical substrate, has a layer of conductive materialthereon that is patterned, e.g., as by photo-etching, to form theelectrical conductors for power, ground, data and the like as desired.Alternatively, the conductor pattern could be printed with anelectrically conductive ink or epoxy or adhesive. Typically, electronicdevices are attached as flip-chip and/or surface mount devices. Ifelectronic devices are to be connected using solder or conductiveadhesive, then balls of solder or conductive adhesive may be depositedon the conductors in the positions where the terminals of the electronicdevices are to connect. The electronic devices are then placed on thesubstrate and connected via their terminals to the substrate. A coating,e.g., an epoxy or ” glop-drop” or “glob-drop” coating, or an insulatingfilm, may be applied thereover to additionally secure the electronicdevices to the substrate and/or to smooth any edges or projections thatmight snag or otherwise interfere with the weaving process. An underfillencapsulation may also be employed. The sheet substrate is then slit orotherwise cut into strips, or is cut in a serpentine pattern, whereineach strip is a length of one or more functional yarn having electricalconductors and electronic devices thereon. Typically, the length of eachstrip is the length of one functional yarn, but may be a multiplethereof

Functional yarn may also be fabricated as a strip or roll of electricalsubstrate having electrical conductors formed thereon or appliedthereto, and having electrical and/or electronic devices attached and/orapplied thereon to provide a functional yarn, which strip or roll mayinclude plural functional yarn and is then slit to separate individuallengths of functional yarn or may include a single width of functionalyarn and so need not be cut or slit or otherwise separated intoindividual functional yarn. Electrical conductors are formed on thestrip and electronic devices connected thereon in like manner to thatdescribed above. Each strip or roll of functional yarn contains manylengths of functional yarn and is cut to the length of one functionalyarn as fed to the loom for weaving. The functional yarn may be coatedas above.

FIGS. 4A, 4B and 4C are plan view schematic diagrams of an exampleembodiment of a circuit carrier 300 including an example electroniccircuit function suitable for a woven fabric as illustrated in FIGS. 1Aand 1B, and FIG. 4D is an isometric view thereof when folded. FIGS. 4Aand 4B illustrate opposite sides of a generally rectangular substrate310, e.g., a short strip of flexible printed circuit, that is folded ator near fold lines 312 into a “U”-shape so that the opposite ends ofsubstrate 310 are substantially parallel, thereby to form carrier 300.Substrate 310 may be folded relatively sharply at or near fold lines 312or may be folded to have a radius formed of the portion of substrate 310between fold lines 312, as desired.

On one side (broad surface) of substrate 310 (FIG. 4A) near oppositeends thereof are respective carrier contacts WAC, WEC for contactingelectrically conductive yarn 120, 140 in the warp and weft of a textileand/or fabric 100′ into which carrier 300 is placed. While as little asone contact may be provided, typically plural contacts WAC and WEC areprovided. Preferably, warp contacts WAC are substantially parallelrectangular contacts having a longer dimension in the direction alongthe length of the electrically conductive warp yarn 120. Parallel warpcarrier contacts WAC are spaced apart a distance about the same as thedistance between adjacent electrically conductive warp yarn 120 havingone or more insulating warp yarn 110 therebetween. Also preferably, andsimilarly, weft contacts WEC are substantially parallel rectangularcontacts having a longer dimension orthogonal to that of warp contactsWAC, i.e. weft contacts WEC are longer in the direction along the lengthof the electrically conductive weft yarn 140. Parallel weft carriercontacts WEC are spaced apart a distance about the same as the distancebetween adjacent electrically conductive warp yarn 140 having one ormore insulating warp yarn 130 therebetween.

On the other side (broad surface) of substrate 310 (FIG. 4B) are mountedone or more electronic devices 160 for performing all or part of anelectronic function. Electronic devices 160 may include integratedcircuits, semiconductors, transistors diodes, sensors, activecomponents, passive components and the like, as necessary and desirablefor performing the desired electronic function, and may include any orall of the devices and functions described in relation to devices 160and/or 170 herein. Typically, ones of electronic devices 160 are ofdifferent sizes and shapes, may be a surface mounted or flip chip type,e.g., using solder or electrically conductive adhesive, and usually, butnot necessarily, comprise devices performing more complex functions,such as microprocessors, encoders and decoders, addressable driversand/or switches, and the like. Typically, devices 160 are interconnectedby metal conductors formed in a pattern on substrate 310 in any suitablemanner, including as for a conventional printed circuit board.Connections through substrate 310 to contacts WAC, WEC may be made byconductive vias and/or by plated through holes and/or by any othersuitable manner.

Substrate 310 with electronic device(s) 160 thereon is folded so thatcontacts WAC, WEC are exposed and devices 160 are enclosed, andpreferably is filled and/or sealed with an encapsulant 320 toencapsulate electronic devices 160 and to maintain the surfaces ofsubstrate 310 containing contacts WAC and WEC in substantially parallelrelationship in carrier 300, as illustrated in FIG. 4D. Optionally,contacts WAC, WEC may be coated with an electrically conductive adhesivethat is set during the weaving process, e.g., described below.

Typically, substrate 310 may be formed of a thin sheet of polyimidematerial with copper printed wiring conductors thereon, or of any of thematerials described in relation to any other substrate. Typically, anumber of substrates are fabricated on a sheet of substrate material,the electrical contact and conductor patterns are formed thereon,electronic devices 160 are mounted, and then individual or rows ofsubstrates 310 are cut from the sheet thereof. Substrates 310 or rows ofsubstrates 310 are then folded and encapsulated with encapsulant 320.Suitable encapsulants include Hysol brand encapsulants available fromHenkel Loctite Corporation located in Industry City, Calif. Typicalexamples of carrier 300 may range in size from about 0.5×0.5×0.1 cm toabout 2.5×2.5×1 cm, but may be larger or smaller, as may be necessaryand/or desirable. Carriers 300 may be utilized, e.g., where anelectronic device 160 is too large to conveniently be mounted tofunctional yarn 150.

Carriers 300 are placed into cavities in a multilayer fabric as thefabric is being woven, and the thread count precision and dimensions ofthe pocket are predetermined so that carrier 310 is a generally snug fitin the pocket, so that conductive yarn 120, 140 in the warp and in theweft align with sufficient precision so as to contact warp and weftcontacts WAC and WEC, respectively. With proper yarn tension and weavedensity, the physical contact between conductive yarn 120, 140 andcontacts WAC, WEC is sufficient to provide reliable electricalconnection therebetween. If desired, electrically conductive adhesive orsolder paste may be applied to the contacts WAC, WEC of carrier 300 formaking a mechanical connection as well as an electrical connectiontherewith.

FIG. 4C illustrates an optional variation of substrate 310 of carrier300 wherein one or more irregularities and/or indentations are providedalong any one or more edges of substrate 310. Such irregularities and/orindentations are provided for guiding conductive yarn 120, 140 intoalignment with contacts WAC, WEC. Examples of suitable irregularitiesinclude “V”-shaped notches 316 and/or curved or circular indentations318. In each example, irregularities 316, 318 are generally aligned withthe long axis of rectangular contacts WAC, WEC in like manner to thedesired alignment of conductive yarn 120, 140 therewith.

FIG. 5 is a partial cross-sectional schematic diagram illustrating anexample circuit carrier 300 disposed in a cavity 106 of a multilayerwoven fabric 100. Carrier 300 is snugly enclosed in cavity 106 withelectrically conductive warp yarn 120 (cross-sectioned with diagonallines) in physical and electrical contact with warp carrier contacts WACin the warp direction and with electrically conductive weft yarn 140 inphysical and electrical contact with weft carrier contacts WEC in theweft direction. Insulated warp yarn 110 and weft yarn 130 are interwoventherewith to define cavity 106. While the illustrated cross-section iscut along the weft direction, a cross-section if cut along the warpdirection would appear similar, although the designations of warp andweft yarn would be interchanged.

It is noted that the tension of the yarn tends to enclose carrier 300snugly and in proper position within cavity 106 so that reliableelectrical connection between electrically conductive warp yarn 120 andcarrier warp contacts WAC, and between electrically conductive weft yarn140 and carrier weft contacts WEC, is provided solely as a result of thephysical contact therebetween, without the need for a solder or anelectrically conductive adhesive connection, although such connectionsmay be employed.

FIGS. 6A and 6B are schematic diagrams illustrating example loomarrangements suitable for making the example embodiments describedherein. Rapier loom 200 weaves warp yarn 210 and weft yarn 220 into afabric or textile 100. Alternate first ones 210 a of the warp yarn 210are raised and second ones 210 b of the warp yarn 210 intermediatetherewith are lowered whilst weft yarn 220 drawn from weft supply 222 ispulled between the raised and lowered warp yarn 210 a, 210 b,respectively, by rapier 230. Comb or reed 214 maintains the spacing andposition of warp yarn 210 in the opening or shed formed by separatedwarp yarn 210 a, 210 b being raised and lowered alternately duringweaving. Typically, rapier 230 is a flexible rapier 230 and is pulledback and forth between rapier capstan wheels 240 for pulling weft yarn220 from weft supply 222 and through the space between raised andlowered warp yarn 210 a, 210 b. Then, the raised first warp yarn 210 aare lowered and the lowered second warp yarn 210 b are raised andanother weft yarn 220 from weft supply 222 is pulled therebetween byrapier 230. Next, the raised second warp yarn 210 b are lowered and thelowered first warp yarn 210 a are raised and another weft yarn 220 fromweft supply 222 is pulled therebetween by rapier 230, and the weavingsequence repeats interweaving warp and weft yarn 210, 220 for weavingfabric/textile 210.

For multilayer weaving, warp yarn 210 in each layer or in part of alayer is raised and lowered in accordance with the desired weave patternas weft yarn 220 is woven therethrough, as is known for conventionalfabrics in the art of weaving. The raising and lowering of warp yarn 210and the weaving of weft yarn 220 produces cavities 106 in the wovenfabric wherein two layers are separately woven in a region defining thecavity 106 and are interwoven in the region surrounding the cavity,thereby to form a closed cavity or pocket 106. As a cavity 106 is woven,a circuit carrier 300 is inserted into each partially woven cavity 106before cavity 106 is woven to closure to surround the carrier 300.Modern, automated computer-controlled looms can rapidly and reliablyraise and lower a few or many warp yarn very rapidly and in complicatedpatterns, as may be desired for weaving cavities 106 in desiredpositions in a fabric.

Warp yarn 210 may include insulating yarn, electrically conductive yarnand/or functional yarn, in any desired sequence. Typically, one or moreinsulating yarn are woven between electrically conductive yarn and/orfunctional yarn to provide physical spacing and electrical insulationbetween adjacent ones thereof.

Where weft supply 222 provides weft yarn 220 of different colors or ofdifferent types, such as insulating yarn, electrically conducting yarnand/or functional yarn, selector 224 selects the appropriate weft yarn220 at the appropriate times for providing the sequence of weft yarndesired for fabric 100. Where weft yarn 220 is electrically conducting,for example, selector 224 selects an insulating yarn 220 for the weftthreads woven prior to and following the insulating yarn, so thatadjacent conductive yarn are not contiguous, but are separated by aninsulating yarn and so are insulated one from the other. In some cases,however, it may be desired that plural conductive yarn be contiguous,e.g., in parallel for increasing current carrying capacity and/orincreasing the reliability of the contact with conductive warp yarnand/or functional warp yarn at the crossings thereof.

Where, for example, it is desired to produce a fabric or textile 100wherein different functional yarn are woven into the weft, either in asingle layer or in a multilayer weave, weft supply 222 providesfunctional weft yarn 220 of different colors or of different types,selector 224 selects the appropriate functional weft yarn 220 at theappropriate times for providing the sequence of weft yarn desired. Oneexample of a fabric employing different functional yarn is a multicolordisplay fabric, as for a two-color, three-color, or full-color display.In such case, weft supply 222 selects the functional weft yarn havingthe appropriate color light emitters thereon. For example, functionalyarn having LEDs producing red light, functional yarn having LEDsproducing green light, and functional yarn having LEDs producing bluelight may be woven into fabric 100 in a red-green-blue sequence forproviding a display fabric having the capability to produce color imageswhen the red, green and blue light emitting elements are activated atsuitable times and at suitable illumination intensities.

FIG. 6B is a schematic diagram illustrating an example capstan 240 androller 242 arrangements suitable for utilization with the example loom200 of FIG. 6A. Capstan wheel rotates clockwise and counterclockwise,i.e. bidirectionally, for feeding any weft yarn in weaving by loom 100.Rollers 242 are spring loaded or otherwise biased so as to press againstcapstan wheel 240 so as to maintain the weft yarn in frictional contacttherewith so that it can be inserted into the weft of the fabric/textilebeing woven by loom 100. In particular, functional weft yarn 150 is sowoven by capstan wheel 240 into the weft of a fabric. So that functionalyarn 150 may be properly positioned with respect to the weft directionof fabric 100, sensor 250 is positioned proximate capstan wheel 240 in alocation where one or more registration indicia 180 of functional yarn150 may be detected. Sensor 250 may be an optical detector for detectingone or more optical (e.g., reflective) indicia on functional yarn 150and/or may be an electrical detector such as a continuity detector fordetecting one or more electrically conductive (e.g., metal contact)indicia 180 of functional yarn 150 and/or may be a mechanical detectorfor detecting one or more mechanical features of functional yarn 150.

Alternatively, an arm attached to loom 100 may be utilized pull the yarnout of the shed to counter the rapier pulling the yarn into the shed,thereby to properly position functional yarn 150 and register elementsthereof. Also alternatively, where the rapier is designed to draw theweft yarn into the shed a predetermined distance with suitabletolerance, registration mark(s) 180 may be utilized to positionfunctional yarn 150 in predetermined manner for subsequently being drawninto the loom by the predetermined rapier distance.

FIG. 7 is a schematic diagram of an example carrier insertionarrangement 260 and an example roller arrangement 270 suitable forweaving and finishing multilayer weave fabric woven in accordance withFIGS. 6A-6B. Carrier insertion is provided, for example, by carrierinsertion rod 260 which moves laterally (as indicated by thedouble-ended arrow) into and out of the shed (reed or comb 214 notshown) for inserting circuit carriers 300 into cavities 106 in fabric100. When the weave has progressed to the point where one or morecavities 106 are partially woven, the weaving of weft yarn by the rapierceases for a short time wherein carrier insertion rod is inserted intothe shed and dispenses circuit carriers 300 in predetermined orientationinto the partially woven cavities 106. When the carriers have beeninserted into the partially woven cavities 106, insertion rod 260 iswithdrawn and weaving of weft yarn resumes to complete the weaving ofcavities 106 enclosing carriers 106.

Carrier insertion rod 260 may dispense one carrier at a time, e.g., asin a pick-and-place operation, or may dispense plural carriers 300 at atime, e.g., as in a contemporaneous pick-and-place operation.Alternatively, insertion rod 260 may include a carrier feed arrangementwherein carriers 300 are fed along insertion rod 260 and are dispensedfrom one or more locations thereon. Any of the foregoing may be employedwhere all of carriers 300 are of like type and/or where carriers 300 areof different types.

Optional roller 270 includes a pair of heated rollers 270 a, 270 bbetween which woven fabric 100 passes as it is woven on loom 200. Wherecircuit carriers 300 include, e.g., thermoplastic and/or thermosettingelectrically conductive adhesive on contacts WAC, WEC for makingconnection thereto, heated rollers 270 a, 270 b apply suitable heat andpressure for melting a thermoplastic adhesive and/or for melting and/orcuring a thermosetting adhesive. Heated rollers 260 may similarly beemployed where such thermoplastic adhesive and/or thermosetting adhesiveis included on contacts of functional yarn 150.

FIG. 8 is a schematic diagram of an example yarn 150 including anexample electronic circuit function suitable for use with the exampleloom arrangements 200 of FIGS. 6A-6B. Functional yarn 150 includes aflexible substrate 152 suitable for carrying electrical and/orelectronic circuits thereon. For example, substrate 152 carries aplurality of electrical circuit components 160 attached thereto andconnecting to conducting circuit traces 154, 156. External connection toconductors 154, 156 of functional yarn 150 is made via one or morecontacts 158, an illustrated example of which is located at or near oneor both ends of substrate 152. Secure and/or permanent connectionthereto may be made, for example, by an electrically conductive adhesive159, such as a thermoplastic or thermosetting adhesive, which istypically filled with electrically conductive particles, which is set orcured under heated compliant pressure pads or rollers. Functional yarn150 also typically includes one or more registration marks or indicia180 located at or near one end of yarn 150 for registering functionalyarn 150, e.g., with respect to the warp yarn when functional yarn 150is utilized in the weft. Such registration of functional yarn 150 is,for example, for positioning contacts 158 in locations in fabric 100wherein they will make electrical connection with conductive yarn in thewarp thereof and/or for positioning electronic devices 160 with respectto each other and fabric 100. To this end, registration indicia 180 isin known predetermined position along the length of substrate 152 offunctional yarn 150 with respect to contacts 158 and/or electroniccomponents/devices 160 thereof. Mark(s)/indicia 180 may be of anydesired shape and may be optically reflective when intended for use withan optical detector and/or may be electrically conductive when intendedfor use with an electrical continuity or conductivity detector.Registration mark(s) 180 may also be utilized for properly aligningfunctional yarn on the loom where functional yarn is utilized in thewarp of the fabric.

FIG. 9 is a schematic diagram of an example woven textile 100illustrating an ordinary weave and a complex weave which may be utilizedin connection with any of the single layer and/or multilayer weavesherein. Example fabric 100 includes insulating yarn 110 and electricallyconductive yarn 120 in the warp and insulating yarn 130 and conductiveyarn 140 in the weft. Ordinarily, electrical connection betweenelectrically conductive yarn 120 in the warp and electrically conductiveyarn 140 in the weft is satisfactorily made by the physical contacttherebetween in a plain weave having a typical tightness and/or densityof yarn, as are connections between conductive yarn 120 and/or 140 and afunctional yarn. Fabric so made have been observed to exhibit stableconnection, e.g., as in bright, stable light from LEDs, under theapplication of shearing forces to the fabric, bending the fabric, andotherwise distorting and/or conforming the fabric shape.

For looser weaves and/or where highly reliable electrical contact isimportant, a more complex weave may be employed. For example, a Lenoweave having plural conductive yarn 120 a and 120 b intertwined as theyare woven to provide an electrically conductive yarn 120′ may beutilized. Because the two conductive yarn 120 a, 120 b wrap aroundconductive yarn 140 (and/or a functional yarn) at locations where theycross, providing a tight weave and a connection of higher reliabilitythereat. While intertwined conductive yarn 120′ is illustrated by way ofexample as being in the warp in the case of a Leno weave, twistedconductive yarn may be utilized in the warp and/or the weft and twistedyarn may be utilized with insulating and/or conductive yarn in otherweaves.

While the electrically conductive yarn and the functional yarn aregenerally orthogonal and cross in a woven fabric or textile, theconductive and functional yarn need not be orthogonal, and conductiveyarn and functional yarn may run in the same weave direction in a fabricor textile. Further, while either or both electrically conductive yarnand functional yarn may be woven in either or both the warp and/or theweft, it is generally preferred that electrically conductive yarn bewoven in the warp and functional yarn be woven in the weft, for example,to permit different functional yarn to be utilized in a fabric/textile.For example, by utilizing a first type of functional yarn containingsensors and/or light sources and a second type of functional yarncontaining processors in the same fabric, a “smart” fabric may be woventhat both senses data and processes the data sensed and/or thatgenerates addressing for illuminating light sources and illuminates theaddressed light sources.

Woven textiles including electronic function as described herein aresuitable for many different applications and/or articles having utilityfor consumer, private, public, professional, commercial, government,military and other entities. Among such are, for example, programmablealpha-numeric signage as for traffic warning, advertising, window signs,banners, portable signs, garments and articles of clothing (e.g., forpeople and/or animals), safety-wear bibs, vests and other safetygarments, footwear, articles and/or garments for a baby and/or aninfant, personal flotation devices, life saving apparatus, blankets,medical devices, light blankets, warming blankets, sensing blankets,apparatus and/or equipment for sport, sports wear, uniforms, toys,entertainment devices, truck and other vehicle signage, constructionand/or work area signs, directional signs, lighting, emergency lighting,lighting panels, decorative lights, accent lights, reading lights,lighting for a tent, tarp, canvas and/or umbrella, display lighting,sensor fabrics, environmental and/or chemical and/or biological agentsensor arrays, camouflage, a parachute, a uniform (e.g., for government,military, sport and/or medical personnel), light sensing arrays, imagingarrays, and any other article including a woven fabric.

In each application, because the article is a woven fabric article ithas the give and drape characteristics of fabric, and so can be hung,draped, folded, rolled or otherwise placed in a non-planar condition.Thus, even very large articles can be folded, rolled up or otherwisestored in a small space. For example, a 2 by 3 meter sign could easilybe folded and/or rolled up and placed in the trunk or other storagecompartment of a vehicle such as a police, fire, ambulance or otheremergency vehicle and/or the storage space of a truck or automobile. Inaddition, a lightweight pop-up support frame, similar to the supportframes employed with a camping tent, may be employed with a textilearticle as described herein. When unfolded, woven fabric articles may bedraped or otherwise placed to conform to a desired surface and/or shape.

The yarn utilized in weaving the fabric may be made wider consistentwith the size of the woven sign and the resolution and/or pixel ordisplay element size desired and/or the capability of the loom (eitheran automated or a manual loom) to weave wide yarn. For example, standardmodern looms can weave yarn up to about 10 mm wide. A large displayand/or sign, such as a banner scoreboard, may be 10 meter long and 1meter wide, and may, e.g., be woven of yarn and functional yarn stripshaving a width of about 2-3 cm. Because the message presented by suchlarge signs and banners is easily changed, one sign or banner can bereused many times for many different purposes, the cost is lower than ifa different printed sign is utilized for each event, and externalillumination is not needed for use during darkness. Signs and bannersmay be rolled, e.g., on a window-shade-type roller for convenient andquick set up and removal, or may simply be folded.

While the present invention has been described in terms of the foregoingexemplary embodiments, variations within the scope and spirit of thepresent invention as defined by the claims following will be apparent tothose skilled in the art. For example, while it is preferred thatcavities in a multilayer woven fabric be closed, i.e. completelysurround a circuit carrier disposed therein, a closed cavity is notmandatory. Open pockets may be employed in which case circuit carrierstherein may be easily removed and inserted after the fabric is woven,thereby facilitating the reconfiguration or modification of the functionof an electronic textile, or for purposes of the repair, maintenance,upgrading and/or updating thereof.

Electrical connection to contacts and/or conductors of functional yarnmay be made directly to the functional yarn at an edge of the fabric ormay be made via crossing conductive yarn to which connections are madeat an edge of the fabric, or a combination of connection arrangementsmay be utilized.

In addition, functional yarn could include an electrically conductivesubstrate on which are placed electronic devices and contacts therefor,wherein an insulating layer and/or a pattern of insulating areas aredisposed on the conductive substrate to provide insulation for suchcontacts. Further, placement and registration of functional yarn in afabric may be to align the electronic devices thereon, or registrationof the functional yarn may be to place such devices in a pattern otherthan an aligned pattern, as might be desirable for an electronicallyfunctional fabric utilized for camouflage.

While sufficient electrical connection between conductive yarn and/orfunctional yarn is typically made at locations where such yarn cross ina fabric, other conductive adhesive such as ultraviolet-cured adhesivemay optionally be employed to improve such connection.

As stated herein, examples of a fabric, textile and/or article having aparticular yarn in one of the warp and weft is intended to describe thefabric, textile and/or article with such yarn in the warp, in the weft,or in the warp and in the weft. Any weave may be employed, including butnot limited to, plain or tabby, twill, overshot, laid-in, leno, gauze,loop, double, multilayer, combinations thereof, and any other weave.

The terms electrical device, electronic device, electrical component andelectronic component are used interchangeably herein, and any one isintended to include any or all of the others. The same is true as to theterms conductor, contact and terminal, e.g., in the context of afunctional yarn and/or electronic device, and the terms “electrical” and“electronic.” Similarly, “optical” devices include, for example, devicesthat detect and/or produce electromagnetic radiation, and/or thatotherwise operate, in the visible, infrared, ultra-violet, x-ray and/orother regions of the electromagnetic spectrum, including a narrow bandthereof such as would define a “color.”

1. A multilayer woven article having an electronic function woventherein comprising: warp yarn and weft yarn interwoven in a multilayerweave having plural layers defining at least one cavity therebetween; atleast one electrically conductive yarn disposed in the warp and/or inthe weft and having a portion thereof in one of the plural layersdefining the at least one cavity; and a circuit carrier disposed in thecavity and having at least one exposed electrical contact in electricalconnection with said at least one electrically conductive yarn, saidcircuit carrier including at least one electronic device for performinga function.
 2. The multilayer woven article of claim 1 furthercomprising at least one functional yarn disposed in one of the warp andthe weft, said functional yarn comprising: an elongate substrateincluding at least one electrical conductor disposed thereon, and atleast one electronic device on said elongate substrate, wherein the atleast one electrical conductor on said elongate substrate electricallyconnects said electronic device of said functional yarn and said atleast one electrically conductive yarn.
 3. The multilayer woven articleof claim 1 wherein said at least one electrically conductive yarn andsaid at least one electrical contact of said circuit carrier are inelectrical contact at a location where said at least one electricallyconductive yarn crosses the contact of said circuit carrier in the wovenarticle without a mechanical attaching thereof at that location.
 4. Themultilayer woven article of claim 1 wherein said at least one electronicdevice of said circuit carrier is addressable by passive matrixaddressing, active matrix addressing, serial addressing, paralleladdressing, scanned addressing, active addressing, block addressing,and/or individual addressing communicated via said at least oneelectrically conductive yarn and the at least one exposed electricalcontact of said circuit carrier.
 5. The multilayer woven article ofclaim 1: wherein said at least one electrically conductive yarn includeselectrically conductive yarn for providing electrical power to saidelectronic device of said circuit carrier via the at least one exposedelectrical contact thereof, and/or wherein said at least oneelectrically conductive yarn includes electrically conductive yarn forproviding electrical power to said electronic device of said circuitcarrier via the at least one exposed electrical contact thereof, andfurther includes a signal and/or data conductor for controlling and/oractivating said at least one electronic device via the at least oneexposed electrical contact of said circuit carrier.
 6. The multilayerwoven article of claim 1 wherein the at least one exposed electricalcontact of said circuit carrier is elongate and is aligned with anelectrically conductive yarn in the warp and wherein a second exposedelectrical contact of said circuit carrier is elongate and is alignedwith an electrically conductive yarn in the weft.
 7. The multilayerwoven article of claim 1 wherein said at least one electronic deviceincludes one or more of a temperature sensor, a chemical sensor, abiological sensor, a sensor of force, pressure, sound, an electricfield, a magnetic field, light, acceleration and/or an environmentalcondition, a source of light, force, heat, electromagnetic radiationand/or sound, an infra red and/or wireless transmitter and/or receiver,an imager, a CCD imager, a thermoelectric sensor, cooler, heater and/orgenerator, a liquid crystal element, an electro-luminescent element, anorganic light-emitting element, an OLED, an electrophoretic element, anLED, a piezo-electric element and/or transducer, a microphone, aloudspeaker, an acoustic transducer, a resistor, a processor, a digitalsignal processor, a microprocessor, a micro-controller, a CPU, ananalog-to-digital converter, a digital-to-analog converter, adata-producing device, a data-utilizing device, a processing device, aswitch, a human-interface device, a human-input device, a blinker and/orflasher, a battery, a fuel cell, a solar cell, a photovoltaic device, apower source, and/or an addressable device.
 8. The multilayer wovenarticle of claim 1 embodied in a fabric, a textile, a consumer article,a professional article, a commercial article, a government article, amilitary article, programmable alpha-numeric signage, a traffic warningsign, an advertising sign, a window sign, a banner, a portable sign, agarment, an article of clothing, an article and/or garment for a babyand/or an infant, a safety-wear bib, a vest, a safety garment, apersonal flotation device, life saving apparatus, footwear, a blanket, amedical device, a light blanket, a warming blanket, a sensing blanket,apparatus and/or equipment for sport, sports wear, a uniform, a toy, anentertainment device, truck signage, vehicle signage, a constructionand/or work area sign, a directional sign, lighting, emergency lighting,a lighting panel, a decorative light, an accent light, a reading light,lighting for a tent, tarp, canvas and/or umbrella, display lighting, asensor fabric, an environmental and/or chemical and/or biological agentsensor array, camouflage, a parachute, a light sensing array, and/or animaging array.
 9. A multilayer woven article having a warp and a weftcomprising: a plurality of electrically insulating and/or uninsulatedelectrically conductive yarn in the warp for defining plural layers; aplurality of electrically insulating and/or uninsulated electricallyconductive yarn in the weft interwoven in a multilayer weave with saidplurality of electrically insulating and/or electrically conductive yarnin the warp for defining a pocket between first and second woven layersthereof, wherein at least one uninsulated electrically conductive yarnin the warp is in the first woven layer defining the pocket and at leastone uninsulated electrically conductive yarn in the weft is in thesecond woven layer defining the pocket; and a circuit carrier disposedin the pocket and having two opposing broad exterior surfaces inphysical contact with the first and second woven layers, said circuitcarrier having at least a first electrical contact on a first of theexterior surfaces and having at least a second electrical contact on asecond of the exterior surfaces, said circuit carrier including at leastone electronic device electrically coupled to said first and secondelectrical contacts, wherein said first electrical contact is inelectrical connection with the at least one uninsulated electricallyconductive yarn in the first woven layer and said second electricalcontact is in electrical connection with the at least one uninsulatedelectrically conductive yarn in the second woven layer.
 10. Themultilayer woven article of claim 9 wherein said first electricalcontact includes a first elongate electrical contact disposed in a firstorientation on the first of the exterior surfaces and wherein saidsecond electrical contact includes a second elongate electrical contactdisposed in a second orientation on the second of the exterior surfaces,wherein the second orientation is transverse to the first orientation.11. The multilayer woven article of claim 9: wherein said at least oneuninsulated electrically conductive yarn in the first woven layer andsaid first electrical contact of said circuit carrier are in electricalcontact at a crossing thereof without a mechanical attaching thereof atthat crossing, and/or wherein said at least one uninsulated electricallyconductive yarn in the second woven layer and said second electricalcontact of said circuit carrier are in electrical contact at a crossingthereof without a mechanical attaching thereof at that crossing.
 12. Themultilayer woven article of claim 9 wherein said at least one electronicdevice of said circuit carrier is addressable by passive matrixaddressing, active matrix addressing, serial addressing, paralleladdressing, scanned addressing, active addressing, block addressing,and/or individual addressing communicated via said at least oneuninsulated electrically conductive yarn and the first and/or secondelectrical contact of said circuit carrier.
 13. The multilayer wovenarticle of claim 9 further comprising at least one functional yarndisposed in one of the warp and the weft adjacent an electricallyinsulating yarn thereof, said functional yarn comprising: an elongatesubstrate including at least one electrical conductor disposed thereon,at least one electronic device on said elongate substrate, wherein theat least one electrical conductor provides directly and/or indirectly anelectrical contact for connecting to said electronic device on saidelongate substrate.
 14. The multilayer woven article of claim 12 whereinsaid at least one functional yarn is interwoven to cross at least oneuninsulated electrically conductive yarn and to connect thereto at thecrossing, wherein the at least one electrical conductor of saidfunctional yarn provides indirectly via said at least one uninsulatedelectrically conductive yarn an electrical connection to said electronicdevice of said functional yarn, and/or wherein the at least oneelectrical conductor of said functional yarn is in electrical contactwith an uninsulated electrically conductive yarn at a location wheresaid functional yarn crosses said uninsulated electrically conductiveyarn in the woven article without a mechanical attaching of saidfunctional yarn and said uninsulated electrically conductive yarn atsaid location.
 15. The multilayer woven article of claim 9 wherein saidat least one electronic device includes one or more of a temperaturesensor, a chemical sensor, a biological sensor, a sensor of force,pressure, sound, an electric field, a magnetic field, light,acceleration and/or an environmental condition, a source of light,force, heat, electromagnetic radiation and/or sound, an infra red and/orwireless transmitter and/or receiver, an imager, a CCD imager, athermoelectric sensor, cooler, heater and/or generator, a liquid crystalelement, an electro-luminescent element, an organic light-emittingelement, an OLED, an electrophoretic element, an LED, a piezo-electricelement and/or transducer, a microphone, a loudspeaker, an acoustictransducer, a resistor, a processor, a digital signal processor, amicroprocessor, a micro-controller, a CPU, an analog-to-digitalconverter, a digital-to-analog converter, a data-producing device, adata-utilizing device, a processing device, a switch, a human-interfacedevice, a human-input device, a blinker and/or flasher, a battery, afuel cell, a solar cell, a photovoltaic device, a power source, and/oran addressable device.
 16. The multilayer woven article of claim 9embodied in a fabric, a textile, a consumer article, a professionalarticle, a commercial article, a government article, a military article,programmable alpha-numeric signage, a traffic warning sign, anadvertising sign, a window sign, a banner, a portable sign, a garment,an article of clothing, an article and/or garment for a baby and/or aninfant, a safety-wear bib, a vest, a safety garment, a personalflotation device, life saving apparatus, footwear, a blanket, a medicaldevice, a light blanket, a warming blanket, a sensing blanket, apparatusand/or equipment for sport, sports wear, a uniform, a toy, anentertainment device, truck signage, vehicle signage, a constructionand/or work area sign, a directional sign, lighting, emergency lighting,a lighting panel, a decorative light, an accent light, a reading light,lighting for a tent, tarp, canvas and/or umbrella, display lighting, asensor fabric, an environmental and/or chemical and/or biological agentsensor array, camouflage, a parachute, a light sensing array, and/or animaging array.
 17. A circuit carrier comprising: an electrical circuitsubstrate having two substantially parallel planar portions defining twoopposing broad exterior surfaces and an internal cavity, said electricalcircuit substrate having at least a first elongate electrical contactdisposed in a first orientation on a first of the exterior surfaces andhaving at least a second elongate electrical contact disposed in asecond orientation on a second of the exterior surfaces, wherein thesecond orientation is transverse to the first orientation; at least oneelectronic device disposed in the internal cavity between the twosubstantially parallel planar portions of said electrical circuitsubstrate, wherein said at least one electronic device is electricallycoupled to said first and second elongate electrical contacts; and anencapsulant substantially filling the internal cavity and encapsulatingsaid at least one electronic device therein.
 18. The circuit carrier ofclaim 17 wherein said electrical circuit substrate is a unitaryelectrical circuit substrate that is folded to define the twosubstantially parallel planar portions; wherein the at least a firstelongate electrical contact disposed on the first of the exteriorsurfaces and the at least a second elongate electrical contact disposedon the second of the exterior surfaces are disposed on a first surfaceof said unitary electrical circuit substrate; and wherein said at leastone electronic device is mounted to a second surface of said unitaryelectronic circuit substrate.
 19. The circuit carrier of claim 17wherein said at least one electronic device includes one or more of atemperature sensor, a chemical sensor, a biological sensor, a sensor offorce, pressure, sound, an electric field, a magnetic field, light,acceleration and/or an environmental condition, a source of light,force, heat, electromagnetic radiation and/or sound, an infra red and/orwireless transmitter and/or receiver, an imager, a CCD imager, athermoelectric sensor, cooler, heater and/or generator, a liquid crystalelement, an electro-luminescent element, an organic light-emittingelement, an OLED, an electrophoretic element, an LED, a piezo-electricelement and/or transducer, a microphone, a loudspeaker, an acoustictransducer, a resistor, a processor, a digital signal processor, amicroprocessor, a micro-controller, a CPU, an analog-to-digitalconverter, a digital-to-analog converter, a data-producing device, adata-utilizing device, a processing device, a switch, a human-interfacedevice, a human-input device, a blinker and/or flasher, a battery, afuel cell, a solar cell, a photovoltaic device, a power source, and/oran addressable device.
 20. A method for weaving a multilayer fabricand/or a textile article having a warp and a weft comprising: providinga plurality of electrically insulating yarn and/or electricallyconductive yarn defining plural layers in the warp; weaving a pluralityof electrically insulating yarn and/or electrically conductive yarn inthe weft in a multilayer weave with said plurality of electricallyinsulating yarn and/or electrically conductive yarn in plural layers inthe warp to define at least one cavity between two layers thereof,wherein at least one electrically conductive yarn in the warp and/or inthe weft is woven in a layer defining the at least one cavity; andplacing a circuit carrier in the at least one cavity, wherein thecircuit carrier includes exposed electrical contacts providingelectrical connection between an electronic device in the circuitcarrier and the at least one electrically conductive yarn in the warpand/or the weft that is woven in the layer defining the at least onecavity.
 21. The method of claim 20 wherein said weaving a plurality ofelectrically insulating yarn and/or electrically conductive yarnincludes controlling a tightness of the weave and/or a density of yarnfor maintaining at least one electrically conductive yarn in the warp inelectrical contact with at least one electrically conductive yarn in theweft at a crossing thereof without mechanically attaching theelectrically conductive yarn thereat.
 22. The method of claim 20 furthercomprising: weaving at least one functional yarn in one of the warp andthe weft adjacent an electrically insulating yarn thereof, wherein thefunctional yarn comprises an elongate substrate including at least oneelectrical conductor disposed thereon and at least one electronic deviceon the elongate substrate and electrically connected to the at least oneelectrical conductor thereon, wherein the at least one electricalconductor and at least one electrically conductive yarn in the other ofthe warp and the weft cross for providing an electrical connection tothe electronic device.
 23. The method of claim 22 wherein the at leastone functional yarn is in the weft and includes at least oneregistration indicia, further comprising: sensing the at least oneregistration indicia of the at least one functional yarn during saidweaving at least one functional yarn; and registering the at least onefunctional yarn in the weft in response to the sensed at least oneregistration indicia.
 24. The method of claim 22 wherein said weaving aplurality of electrically insulating yarn and/or electrically conductiveyarn and said weaving at least one functional yarn include controlling atightness of the weave and/or a density of yarn for maintaining the atleast one electrical conductor of the functional yarn in electricalcontact with an electrically conductive yarn at a location where thefunctional yarn crosses the electrically conductive yarn in the wovenfabric and/or article without mechanically attaching the functional yarnand the electrically conductive yarn at that location.
 25. The method ofclaim 20 wherein said weaving a plurality of electrically insulatingyarn and/or electrically conductive yarn in the weft in a multilayerweave with said plurality of electrically insulating yarn and/orelectrically conductive yarn in plural layers in the warp to define atleast one cavity between two layers thereof comprises: partially weavingthe at least one cavity; then said placing a circuit carrier in the atleast one cavity; and then further weaving the at least one cavity toenclose the circuit carrier therein.
 26. A method for weaving a fabricand/or a textile article having a warp and a weft comprising: providinga plurality of electrically insulating yarn and/or electricallyconductive yarn in the warp; weaving a plurality of electricallyinsulating yarn and/or electrically conductive yarn in the weft withsaid plurality of electrically insulating yarn and/or electricallyconductive yarn in the warp; weaving at least one functional yarn havinga registration indicia in the weft adjacent an electrically insulatingyarn thereof, wherein the functional yarn comprise an elongate substrateincluding at least one electrical conductor disposed thereon am at leastone electronic device on the elongate substrate and electricallyconnected to the at least one electrical conductor thereon; sensing theregistration indicia of the at least one functional yarn during saidweaving at least one functional yarn; and registering the at least onefunctional yarn in the weft in response to the sensed at least oneregistration indicia, wherein the at least one electrical conductor andat least one electrically conductive yarn in the other of the warp andthe weft cross for providing an electric; connection to the electronicdevice.
 27. The method of claim 26 wherein said weaving a plurality ofelectrically insulating yarn and/or electrically conductive yarn andsaid weaving at least one functional yarn include controlling atightness of the weave and/or a density of yarn for maintaining the atleast one electrical conductor of the functional yarn in electriccontact with an electrically conductive yarn at a location where thefunctional yarn crosses the electrically conductive yarn in the wovenfabric and/or article without mechanically attaching the functional yarnand the electrically conductive yarn at the location.
 28. The wovenarticle of claim 2 wherein said at least one functional yarn has aregistration indicia thereon for registering said at least onefunctional yarn with said at least one electrically conductive yarn tosaid connect said electronic device of said functional yarn and said atleast one electrically conductive yarn.